U.S. patent application number 12/557575 was filed with the patent office on 2010-03-18 for blanket-like laminate for insulating surfaces.
This patent application is currently assigned to Guardian Building Products, Inc.. Invention is credited to Gary E. Romes.
Application Number | 20100065206 12/557575 |
Document ID | / |
Family ID | 41820809 |
Filed Date | 2010-03-18 |
United States Patent
Application |
20100065206 |
Kind Code |
A1 |
Romes; Gary E. |
March 18, 2010 |
Blanket-Like Laminate for Insulating Surfaces
Abstract
An insulation product is comprised of a fibrous layer
pre-assembled with a flexible foam layer. The layer containing the
fibrous material may comprise a fiberglass layer or a layer
containing cellulosic fibers. The foam layer, on the other hand,
may comprise any suitable flexible foam, such as an elastomeric
polyurethane foam, that creates an air barrier. The two materials
are laminated together and the resulting product is delivered to a
building or structure for installation.
Inventors: |
Romes; Gary E.; (Greer,
SC) |
Correspondence
Address: |
DORITY & MANNING, P.A.
POST OFFICE BOX 1449
GREENVILLE
SC
29602-1449
US
|
Assignee: |
Guardian Building Products,
Inc.
Greer
SC
|
Family ID: |
41820809 |
Appl. No.: |
12/557575 |
Filed: |
September 11, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61096560 |
Sep 12, 2008 |
|
|
|
Current U.S.
Class: |
156/293 ; 156/60;
428/220; 428/304.4; 428/314.4; 428/318.4; 428/319.1; 428/426;
428/446; 428/532 |
Current CPC
Class: |
B32B 37/203 20130101;
B32B 2305/022 20130101; B32B 5/24 20130101; B32B 37/1284 20130101;
B32B 17/02 20130101; Y10T 428/24999 20150401; Y10T 428/249987
20150401; B29K 2075/00 20130101; Y10T 428/249953 20150401; E04B
1/7662 20130101; B32B 19/04 20130101; Y10T 156/10 20150115; B32B
2038/0084 20130101; B32B 2307/304 20130101; B29K 2995/0015
20130101; E04B 1/7654 20130101; B29C 44/321 20161101; Y10T
428/249976 20150401; Y10T 428/31971 20150401; B32B 27/40
20130101 |
Class at
Publication: |
156/293 ;
428/426; 428/532; 428/446; 428/220; 428/314.4; 428/319.1;
428/318.4; 428/304.4; 156/60 |
International
Class: |
B32B 37/00 20060101
B32B037/00; B32B 17/02 20060101 B32B017/02; B32B 23/02 20060101
B32B023/02; B32B 5/02 20060101 B32B005/02; B32B 5/00 20060101
B32B005/00; B32B 5/18 20060101 B32B005/18 |
Claims
1. A spirally wound insulation product configured to be unwound and
applied to a surface for insulating the surface comprising a first
layer laminated to a second layer, the first layer comprising a
fibrous insulation material comprising a batt of fibers, the second
layer comprising an air barrier layer.
2. A spirally wound insulation product as defined in claim 1,
wherein the fibrous insulation material contains glass fibers.
3. A spirally wound insulation product as defined in claim 1,
wherein the fibrous insulation material contains cellulosic fibers
or stone wool fibers.
4. A spirally wound insulation product as defined in claim 2,
wherein the first layer has a first surface and a second surface,
the first surface being laminated to a backing material, the second
surface being laminated to the air barrier layer, the fibrous
insulation material being in direct contact with the air barrier
layer.
5. A spirally wound insulation product as defined in claim 1,
wherein the product has a width of at least about eight inches.
6. A spirally wound insulation product as defined in claim 1,
further comprising an adhesive attaching the first layer to the
second layer.
7. A spirally wound insulation product as defined in claim 1,
wherein the first layer is laminated to the second layer without
using an adhesive.
8. A spirally wound insulation product as defined in claim 1,
wherein the air barrier layer comprises a flexible foam material
comprising a closed cell foam.
9. A spirally wound insulation product as defined in claim 1,
wherein the air barrier layer comprises a flexible foam material
comprising an open cell foam.
10. A spirally wound insulation product as defined in claim 1,
wherein the air barrier layer comprises a flexible foam material
comprising a polyurethane foam.
11. A spirally wound insulation product as defined in claim 10,
wherein the first layer has a thickness of from about two inches to
about 12 inches and wherein the second layer has a thickness of
from about 0.1 inches to about 2 inches.
12. A spirally wound insulation product as defined in claim 1,
wherein the air barrier layer comprises an elastomeric foam.
13. A spirally wound insulation product as defined in claim 1,
wherein the second layer is formed in-situ on the first layer by
spraying a foam-making composition onto the first layer.
14. A spirally wound insulation product as defined in claim 10,
wherein the foam material is formed by reacting an aromatic
isocyanate with a polyol.
15. A method of insulating a surface comprising unwinding the
insulation product defined in claim 1 onto the surface.
16. A method as defined in claim 15, wherein the surface defines
cavities having opposing side walls and wherein the insulation
product is installed in the cavities so as to form a tension fit
against the opposing side walls of the cavities.
17. An insulation product for later applying to a surface in order
to insulate the surface comprising a first layer laminated to a
second layer, the first layer comprising a fibrous insulation
material comprising a batt of fibers, the first layer having a
first surface and a second surface, the first surface being
laminated to a backing material, the second layer laminated to the
first layer comprising an air barrier layer comprising a flexible
foam material, the foam material being laminated to the second
surface of the first layer, the foam material being in direct
contact with the fibrous insulation material, the foam material
comprising a polyurethane foam, and wherein the first layer has a
thickness of from about 2 inches to about 12 inches and the second
layer has a thickness of from about 0.25 inches to about 2
inches.
18. An insulation product as defined in claim 17, wherein the foam
material comprises an open cell foam.
19. An insulation product as defined in claim 17, wherein the foam
material comprises a closed cell foam.
20. An insulation product as defined in claim 17, wherein the foam
material comprises an elastomeric foam.
21. An insulation product as defined in claim 17, wherein the first
layer is laminated to the second layer without using an adhesive.
Description
RELATED APPLICATIONS
[0001] The present application is based on and claims priority to
U.S. Provisional Patent Ser. No. 61/096,560, filed on Sep. 12,
2008.
BACKGROUND
[0002] Properly insulating structures such as buildings and homes
continues to gain in importance especially in view of rising energy
costs. One of the most common ways to insulate buildings and homes
is to install batts of fiberglass or blown fiberglass insulation
around the exterior walls of the structure. For example, fiberglass
insulation materials are typically used to insulate attics, crawl
spaces, and vertical wall cavities. Such materials have been found
well suited to preventing heat from escaping from the insulated
area in colder months and cool air from escaping from the area in
hotter months.
[0003] Although fiberglass insulation materials have very desirable
R-values in static conditions, the thermal performance of the
materials significantly decreases when subjected to air flow. Thus,
in the past, builders have applied a spray foam material, such as a
polyurethane foam, to a surface to be insulated prior to installing
fiberglass insulation. The rigid polyurethane foam has been found
to serve as an effective air flow barrier while also providing
other beneficial insulation characteristics.
[0004] Fiberglass and foam insulation systems, however, typically
require a two-step process to install. First, for instance, the
rigid polyurethane foam is applied to the surface to be insulated
followed by installing fiberglass batts or loose fill. The
polyurethane foam is typically formed on site by mixing a polyol
with an isocyanate. Isocyanates used in the past have typically
comprised aromatic isocyanates, such as diphenylmethane
diisocyanate (MDI) or toluene diisocyanate (TDI). Specifically, in
order to form a foam, the isocyanate component is combined with a
polyol in the presence of a blowing agent and sprayed out of a
nozzle onto the surface to be treated.
[0005] As can be appreciated, installing a fiberglass and foam
insulation system can become very labor intensive. In particular,
the process of insulating the surface requires two separate
installations for the two different materials.
[0006] In addition, when producing polyurethane foams as described
above, installers are typically required to wear respiratory
protection in order to avoid breathing any unreacted isocyanate.
For example, the United States Environmental Protection Agency
indicates that short-term inhalation of high concentrations of
aromatic isocyanates may cause sensitization and asthma. Further,
dermal contact with aromatic isocyanates has been found to induce
dermatitis and eczema in workers. Long-term inhalation exposure to
isocyanates has also been shown to cause asthma, dyspnea and other
respiratory impairments.
[0007] Thus, when installing polyurethane foams as described above,
workers are typically required to wear a Powered Air Purifying
Respirator (PAPR) or some other type of respirator that provides a
filtered air supply. Further, when applying the foam using a high
pressure system, typically a full body suit is recommended to be
worn. The above respirators and protective garments are very
expensive and very bulky and cumbersome to wear, especially in hot
weather.
[0008] In view of the above, a need currently exists for a fibrous
material and air barrier capable of being installed in a single
step. In addition, a need also exists for a foam insulation system
capable of being installed without exposing the installation
workers to airborne isocyanates.
SUMMARY
[0009] In general, the present disclosure is directed to a process
and system for installing multiple layers of insulation materials
on a surface. The surface, for instance, may comprise a portion of
a building, a home, or other similar structure. The surface, for
instance, may be part of an attic, a crawl space, a vertical wall,
or the like. In accordance with the present disclosure, an air
barrier, such as a flexible foam material, is laminated to a
fibrous material off-site. The pre-assembled insulation layers are
then cut to width and installed on a surface of a building or
structure. Through the present disclosure, a fibrous insulation
layer and air barrier can be installed on a surface in a single
application step. In addition, the insulation product can be
installed without having to wear any extensive respiratory
protection systems.
[0010] For example, in one embodiment, the present disclosure is
directed to an insulation product that comprises a pre-assembled
laminate. In one embodiment, for instance, the insulation product
can be spirally wound and can be configured to be unwound and
applied to a surface for insulating the surface. Alternatively, the
insulation product may be produced and sold in separate pieces that
are stacked together prior to application. The separate pieces, for
instance, may have a length of from about 4 feet to about 15 feet
in length, with any suitable width. The insulation product includes
a first layer laminated to a second layer.
[0011] The first layer, for instance, comprises a fibrous
insulation material comprising a batt of fibers. The batt, for
example, may comprise a fiberglass material, a cellulosic material,
or stone wool fibers, such as rock wool fibers. The second layer,
on the other hand, comprises an air barrier layer. The air barrier
layer may be made from a flexible foam material. The foam material,
for instance, may comprise a closed cell foam or an open cell foam.
In one embodiment, the foam material is made from an elastomeric
foam. Any suitable foam material may be used, such as a
polyurethane foam.
[0012] In addition to foams, it should be understood that the air
barrier layer can be made from various other flexible materials.
For example, the air barrier layer can be made from any flexible
material capable of inhibiting air flow. Such materials may include
thermoplastic films, elastomeric films, rubber materials, and the
like.
[0013] In one embodiment, the fibrous insulation material includes
a first surface and an opposite second surface. The first surface
may be laminated to a backing material, such as a paper or film
material. The second surface of the fibrous insulation material, on
the other hand, can be laminated to the air barrier layer. In one
embodiment, the fibrous insulation material can be placed in direct
contact with the flexible foam material.
[0014] The fibrous insulation material can be attached to the air
barrier layer using any suitable technique. In one embodiment, for
instance, the two layers may be mechanically attached together.
Alternatively, the foam material may be formed directly on the
fibrous insulation material. In this embodiment, no adhesive may be
needed. In still another embodiment, an adhesive may be used in
order to attach the two layers together. The adhesive may comprise
any suitable adhesive, such as a hot melt adhesive.
[0015] The insulation product may have any suitable dimensions
depending upon the particular application and the desired result.
In one embodiment, for instance, the fibrous insulation material
may have a thickness of from about 2 inches to about 12 inches. The
thickness of the air barrier layer, on the other hand, can vary
dramatically depending upon the type of material used to form the
layer. For example, air barrier layers made from film-like
materials can have thicknesses of from about 1 mil to about 250
mils, such as from about 3 mils to about 15 mils. When made from a
foam material, on the other hand, the air barrier layer can have a
thickness of from about 0.1 inches to about 4 inches. The
insulation product can be cut so as to have a desired width. In one
embodiment, for instance, the width of the product can be from
about 6 inches to about 24 inches. In one embodiment, the surface
to be insulated may define cavities where the insulation product is
to be installed. In this embodiment, the insulation product can
have a width so as to form a tension fit against opposing side
walls in the cavities.
[0016] As described above, in one embodiment, the flexible foam
material may comprise a polyurethane foam. The polyurethane foam
may be formed, for instance, by reacting together an aromatic
isocyanate with a polyol.
[0017] Other features and aspects of the present disclosure are
discussed in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] A full and enabling disclosure of the present invention,
including the best mode thereof to one skilled in the art, is set
forth more particularly in the remainder of the specification,
including reference to the accompanying figures, in which:
[0019] FIG. 1 is a perspective view of one embodiment of an
insulation product made in accordance with the present
disclosure;
[0020] FIG. 2 is a side view of one embodiment of a process for
forming an insulation product in accordance with the present
disclosure;
[0021] FIG. 3 is a side view of another embodiment of a process for
forming an insulation product in accordance with the present
disclosure; and
[0022] FIG. 4 is a cross-sectional view of the insulation product
illustrated in FIG. 1 installed in a cavity associated with a
surface that has been insulated in accordance with the present
disclosure.
[0023] Repeat use of reference characters in the present
specification and drawings is intended to represent the same or
analogous features or elements of the present invention.
DETAILED DESCRIPTION
[0024] It is to be understood by one of ordinary skill in the art
that the present discussion is a description of exemplary
embodiments only, and is not intended as limiting the broader
aspects of the present invention.
[0025] In general, the present disclosure is directed to a
multi-layer insulation product for insulating the surfaces of a
building or structure. The insulation product, for instance, may
include a fibrous layer laminated to an air barrier, such as a foam
layer. The fibrous layer has excellent insulation properties under
static conditions. The foam layer, on the other hand, further
improves the insulation properties of the overall material while
also serving as an air barrier to prevent air from flowing through
the fibrous layer. In accordance with the present disclosure, the
multiple layers are pre-assembled and laminated together prior to
installation.
[0026] The insulation product of the present disclosure provides
various advantages and benefits. For example, the insulation
product can be used to insulate a surface in a single installation
step. In the past, on the other hand, similar materials were
installed in a two-step process in which the foam material was
first applied to a surface followed by a fibrous batt of
insulation. The insulation product of the present disclosure, on
the other hand, can more efficiently be installed in a single step
process that dramatically reduces labor requirements.
[0027] In addition, the insulation product of the present
disclosure can be installed without the installers having to wear
any extensive or complicated respirators. In particular, since the
foam material is formed off-site, installation of the insulation
product of the present disclosure does not create any significant
airborne health hazards that have been associated with on-site
formed polyurethane foams in the past.
[0028] Referring to FIG. 1, for instance, one embodiment of an
insulation product 10 made in accordance with the present
disclosure is illustrated. As shown, in this embodiment, the
insulation product 10 comprises a spirally wound product.
Specifically, after the material is produced, the material is wound
into rolls for convenient delivery to the location where the
product is to be installed. In order to install the product, the
roll is unwound and cut to length.
[0029] Alternatively, the insulation product 10 can be cut to a
desired length and then stacked prior to shipping to the location
where the product is to be installed. In this embodiment, the
insulation product can be cut into squares, rectangles, or in any
other suitable shape. In one embodiment, for instance, the
insulation product may be cut into strips having a length of from
about 2 feet to about 20 feet, such as from about 5 feet to about
12 feet.
[0030] The insulation product 10 as shown in FIG. 1 generally
includes a first layer of insulation material 12 laminated to a
second layer of insulation material 14. In one embodiment, the
first layer 12 comprises a fibrous insulation material. For
instance, the first layer 12 may comprise a batt of fiberglass
insulation. Alternatively, the first layer 12 may comprise a batt
of cellulosic fibers, stone wool fibers or mixtures thereof.
[0031] In one embodiment, the first layer 12 of fibrous insulation
material may optionally include a backing layer 16. The backing
layer can be included to provide integrity to the product and to
assist in manipulating the product during insulation. The backing
layer 16, for instance, may comprise a paper material, a polymer
film, or a combination thereof.
[0032] The second layer of material 14 generally comprises an air
barrier layer that prevents air from circulating through the first
layer of material 12 and reducing the insulating properties of the
first layer. The second layer of material 14 can also have
insulation properties as well.
[0033] In one embodiment, the second layer of material 14 is made
from a flexible foam material, such as an elastomeric foam. Foam
materials that may be used include, for instance, polyurethane
foams, polyether foams, silicone foams, polyester foams,
vinyl/polyvinylchloride foams, natural rubber foams, and the like.
The foam material can have an open cell structure although, in one
embodiment, the foam desirably has a closed cell structure.
[0034] In addition to foams, any suitable air barrier material may
be used. For instance, in other embodiments, the second layer of
material 14 may comprise a film. The film can be made from a
thermoplastic polymer, an elastomeric polymer, and/or a rubber
material. The film, for instance, can have a thickness from about 3
mm to about 5 cm.
[0035] When the air barrier comprises a foam material, the
dimensions and properties of the fibrous material layer 12 and the
foam layer 14 can vary dramatically depending upon the particular
application and the desired result. For exemplary purposes only, in
one embodiment, the fibrous material layer 12 may have a thickness
of from about 2 inches to about 12 inches, such as from about 4
inches to about 10 inches. The second layer 14, on the other hand,
may have a thickness of generally from about 0.25 inches to about 2
inches, such as from about 0.5 inches to about 1 inch.
[0036] Insulation products are typically rated in the building
industry by an R-value.
[0037] The higher the R-value, the greater the insulation
properties. The R-value of a material is a measure of apparent
thermoconductivity and thus describes the rate that heat energy is
transferred through a material or assembly. The insulation product
10 as shown in FIG. 1 can generally have any desirable R-value
depending upon the thickness of the materials. Fibrous materials,
such as fiberglass, for instance, typically have an R-value of from
about 3.5 to about 4 per inch. In this regard, the first layer 12,
for instance, made from the fibrous material can have an R-value of
from about R-10 to about R-40.
[0038] The second layer of material 14, on the other hand, can have
a relatively low R-value or a relatively high R-value depending
upon the material used. Foam materials, for instance, can have an
R-value of from about 3 to about 6 per inch depending upon whether
the foam is open cell or closed cell. Thus, the second layer of
material 14, depending upon the thickness of the material, can have
an R-value of from about R-2 to about R-40, such as from about R-3
to about R-20.
[0039] The overall R-value of the insulation product 10 can
generally range from about R-12 to about R-50, or even higher
depending upon the particular application.
[0040] In general, the first layer 12 can be laminated to the
second layer 14 using any suitable technique. The layers can be
laminated together in one embodiment using an adhesive.
Alternatively, an adhesive may not be necessary. In another
embodiment, the first layer 12 may be attached to the second layer
14 using a mechanical attachment structure.
[0041] As shown in FIG. 2, in one embodiment, an air barrier such
as a preformed layer of foam material 14 can be laminated to a
fibrous layer 12 by applying an adhesive in between the two layers
are they are moving down a processing line. For example, as shown
in FIG. 2, a nozzle 20 is shown to apply the adhesive material.
[0042] In general, any suitable adhesive may be used. For instance,
in one embodiment, the two materials may be laminated together
using a hot melt adhesive. Suitable hot melt adhesives include
polyolefin adhesives such as those based on polypropylene or
polyethylene, adhesives containing ethylene vinyl acetate
copolymers, adhesives containing styrene-isoprene-styrene
copolymers, adhesives containing styrene-butadiene-styrene
copolymers, adhesives containing ethylene ethyl acrylate copolymers
and adhesives containing polyurethane reactives.
[0043] The adhesive material can be applied to the first layer 12
and then laminated to the second layer 14, may be applied to the
second layer 14 and then laminated to the first layer 12, or may be
applied to both layers as they are laminated together. In the
embodiment illustrated in FIG. 2, the adhesive material is sprayed
onto the materials. In other embodiments, however, the adhesive
material may be printed on one of the layers, extruded onto one of
the layers, or applied using any other suitable technique. The
adhesive may be applied so as to uniformly cover a surface of one
of the materials, may be applied as discrete islands on one of the
materials or can be applied in a reticulated pattern.
[0044] Once the adhesive material is applied in between the layers,
the layers may be compressed in order to ensure proper bonding. In
other embodiments, however, compression may not be needed.
[0045] Referring to FIG. 3, another embodiment of a method for
forming the insulation product of the present disclosure is
illustrated. In this embodiment, the air barrier such as a foam
layer 14 is formed directly on the fibrous material layer 12. In
particular, the materials used to form the foam material 14 are
sprayed through a nozzle 22 directly onto the fibrous layer 12. Of
particular advantage, many foam materials have inherent adhesive
properties during formation. Thus, in this embodiment, the use of
an adhesive may not be necessary since the foam material may form a
bond with the fibrous layer 12 during production of the foam.
[0046] In one embodiment, the foam material 14 formed directly on
the fibrous layer 12 may comprise a polyurethane foam formed from
two components. For example, the nozzle 22 may be placed in
communication with a first pressurized container containing a first
component typically referred to as the "A" component and a second
pressurized container containing a second component typically
referred to as the "B" component. The two components are combined
in the nozzle 22 and formed into a foam which, as shown, is
directly applied to the surface of the fibrous layer 12.
[0047] When the two components are combined in the nozzle 22, an
exothermic reaction takes place as the resulting material is
emitted from the nozzle. Small bubbles form during the reaction
which become trapped in the newly formed material. As the foam is
applied to the surface of the fibrous layer 12, the foam hardens.
In one embodiment, the foam may expand as it solidifies. The amount
of expansion can be controlled depending upon the particular
reactants being used.
[0048] The polyurethane foam 14 contained in the insulation product
is flexible and, for instance, may comprise an elastomeric foam. In
order to form the polyurethane foam, the A component generally
contains an isocyanate, while the B component contains a polyol.
The isocyanate used in the A component can vary depending upon the
particular application. In one embodiment, the isocyanate is an
aromatic isocyanate. Examples of aromatic isocyanates, include, for
instance, diphenylmethane diisocyanate (MDI), toluene diisocyanate
(TDI), mixtures thereof, or any of their oligomers, pre-polymers,
dimmers, trimers, allophanates, or uretidiones.
[0049] Other isocyanates that may be used include hexamethylene
diisocyanate (HMDI), HDI, IPDI, TMXDI
(1,3-bis-isocyanato-1-methylene ethylene benzene), or any of their
oligomers, pre-polymers, dimmers, trimers, allophanates and
uretidiones.
[0050] Suitable polyisocyanates include, but are not limited to,
toluene-2,4-diisocyanate, toluene-2,6-diisocyanate, (this is TDI
80/20 from above) commercial mixtures of toluene-2,4- and
2,6-diisocyanates, ethylene diisocyanate, ethylidene diisocyanate,
propylene-1,2-diisocyanate, cyclohexylene-1,2-diisocyanate,
cyclohexylene-1,4-diisocyanate, m-phenylene diisocyanate,
3,3'-diphenyl-4,4'-biphenylene diisocyanate, 4,4'-biphenylene
diisocyanate, 3,3'-dichloro-4,4'-biphenylene diisocyanate,
1,6-hexamethylene diisocyanate, 1,4-tetramethylene diisocyanate,
1,10-decamethylene diisocyanate, 1,5-naphthalenediisocyanate,
cumene-2,4-diisocyanate, 4-methoxy-1,3-phenylenediisocyanate,
4-chloro-1,3-phenylenediisocyanate,
4-bromo-1,3-phenylenediisocyanate,
4-ethoxy-1,3-phenylenediisocyanate, 2,4'-diisocyanatodiphenylether,
5,6-dimethyl-1,3-phenylenediisocyanate,
2,4-dimethyl-1,3-phenylenediisocyanate,
4,4'-diisocyanatodiphenylether, benzidinediisocyanate,
4,6-dimethyl-1,3-phenylenediisocyanate,
9,10-anthracenediisocyanate, 4,4'-diisocyanatodibenzyl,
3,3'-dimethyl-4,4'-diisocyanatodiphenylmethane,
2,6-dimethyl-4,4-diisocyanatodiphenyl, 2,4-diisocyanatostilbene,
3,3'-dimethyl-4,4'-diisocyanatodiphenyl,
3,3'-dimethoxy-4,4'-diisocyanatodiphenyl, 4,4'-methylene
bis(diphenylisocyanate), 4,4'-methylene is(dicyclohexylisocyanate),
isophorone diisocyanate, PAPI (a polymeric diphenylmethane
diisocyanate, or polyaryl polyisocyanate),
1,4-anthracenediisocyanate, 2,5-fluorenediisocyanate,
1,8-aphthalenediisocyanate and 2,6-diisocyanatobenzfuran.
[0051] Also suitable are aliphatic polyisocyanates such as the
triisocyanate Desmodur N-100 sold by Mobay (Mobay no longer exists,
a BAYER company now) which is a biuret adduct of
hexamethylenediisocyanate; the diisocyanate Hylene W sold by du
Pont, which is 4,4'-dicyclohexylmethane diisocyanate; the
diisocyanate IPDI or Isophorone Diisocyanate sold by Thorson
Chemical Corp., 25 which is
3-isocyanatomethyl-3,5,5-trimethylcyclohexyl isocyanate; or the
diisocyanate THMDI sold by Verba-Chemie, which is a mixture of
2,2,4- and 2,4,4-isomers of trimethyl hexamethylene
diisocyanate.
[0052] Further examples of suitable isocyanate components include
2,4-tolylenediisocyanate, 2,6-tolylenediisocyanate,
4,4'-diphenylmethanediisocyanate, 4,4'-diphenylthere-diisocyanate,
m-phenylenediisocyanate, 1,5-naphthalene-diisocyanate,
biphenylenediisocyanate, 3,3'-dimethyl-4,4'
biphenylenediisocyanate, dicyclohexylmethane-4,4' diisocyanate,
p-xylylenediisocyanate, bis(4-isocyanatophynyl) sulfone,
isopropylidene bis(4-phenylisocyanate), tetramethylene
diisocyanate, isophorone diisocyanate, ethylene diisocyanate,
trimethylene, propylene-1,2-diisocyanate, ethylidene diisocyanate,
cyclopentylene-1,3-diisocyanates, 1,2-,1,3- or 1,4 cyclohexylene
diisocyanates, 1,3- or 1,4-phenylene diisocyanates, polymethylene
ployphenylleisocyanates, bis(4-isocyanatophenyl)methane,
4,4'-diphenylpropane diisocyanates, bis(2-isocyanatoethyl)
carbonate, 1-methyl-2,4-diisocyanatocycloheane, chlorophenylene
diisocyanates, triphenylmethane-4,4'4''-triisocyanate, isopropyl
benzene-a-4-diisocyanate, 5,6-diisocnanatobutylbicyclo
[2.2.1]hept-2ene, hexahydrotolylene diisocyanate,
1-methoxyphenyl-2,4-diisocyanate, 4,4'4''-triphenylmethane
triisocyanate, polymethylene polyohenylisocyanate,
tolylene-2,4,6-triisocyanate,
4,4'-dimethyldiphenylmethane-2,2'5,5'-tetraisocyanate, and mixtures
thereof.
[0053] As described above, the B component combined with the
isocyanate generally contains a polyol. As used herein, the term
"polyol" refers to a molecule that contains more than one hydroxyl
group. The particular polyol chosen may depend upon various factors
and the amount of flexibility required in the resulting product. In
one embodiment, a mixture of polyols may be used.
[0054] Examples of polyols that can be used in the B component
include polyether polyols including diols and triols, polyester
polyols, polycarbonate polyols, polyacetal polyols, polyolefin
polyols, caprolactone-based polyols, and the like.
[0055] In one embodiment, for instance, a polyoxypropylene polyol,
a polyoxyethylene polyol or a poly(oxyethylene-oxypropylene) polyol
may be used. For example, one commercially available polyether
triol that may be included in the B component is sold under the
trade name XD 1421, which is made by the Dow Chemical Company. It
has a molecular weight of around 4900, and is composed of a ratio
of three oxyethylene units randomly copolymerized per one unit of
oxypropylene. This is commonly called ethylene oxide above and
propylene oxide for the later. It has a hydroxy content of 0.61
meq. OH/g. Another example of a material which is commercially
available is Pluracol.RTM. V-7 made by BASF Wyandotte which is a
high molecular weight liquid polyoxyalkylene polyol. Other polyols
which might be used at polyether polyols such as Pluracol 492 from
BASF, having a molecular weight of 2000.
[0056] Polyester polyols that may be used are generally prepared
from the condensation of a saturated or unsaturated mono- or
poly-carboxylic acid and a polyhydric alcohol. Examples of suitable
polyhydric alcohols include the following: glycerol;
pentaerythritol; mannitol; trimethylolpropane; sorbitol;
methyltrimethylolmethane; 1,4,6-octanetriol; ethylene glycol,
diethylene glycol, propylene glycol butanediol; pentanediol;
hexanediol; dodecanediol; octanediol; chloropentanediol, glycerol
monoallyl ether glycerol; monoethyl ether; triethylene glycol;
2-ethyl hexanediol-1,4; 3,3'-thiodipropanol;
4,4'-sulfonyldihexanol; cyclohexanediol-1,4; 1,2,6-hexanetriol,
1,3,5 hexanetriol; polyallyl alcohol; 1,3-bis (2-hydroxyethoxy)
propane; 5,5'-dihydroxydiamyl ether; 2,5-dipropanol
tetrahydrofuran-2,5-dipentanol, 2,5-dihydroxytetrahydro furan;
tetrahydropyrrole-2,5 propanol; 3,4-dihydroxy tetrahydropyran;
2,5-dihydroxy-3,4-dihydro-1,2 pyran; 4,4'-sulfinyldipropanol;
2,2-bis(4-hydroxyphenyl)-propane; 2,2'-bis(4-hydroxyphenyl)methane,
and the like.
[0057] Examples of polycarboxylic acids include the following:
phthalic acid, isophthalic acid; tetrachlorophthali acid; maleic
acid; dodecylmaleic acid; octadecenylmalei acid; fumaric acid;
aconitic acid, itaconic acid, trimellitic acid; tricarballylic
acid; 3,3'-thiodipropionic acid; 4,4'-sulfonyl-dihexanoic acid;
3-octenedioic-1,7 acid; 3-methyl-3decenedioic acid; succinic acid;
adipic acid; 1,4-cyclohexadiene-1,2-dicarboxylic acid;
3-methyl-3,5-cyclohexadiene 1,2-dicarboxylic acid;
8,12-eicosadienedioic acid; 8-vinyl 10-octadecenedioic acid; and
the corresponding acid anhydrides, acid chlorides, and acid esters
such as phthalic anhydride, phthaloyl chloride, and the dimethyl
ester of phthalic acid. Other polyols may be used herein such as
specialty types that are not considered as being purely polyester
polyol.
[0058] Particular polyester polyols which may be used include
hydroxyl-terminated reaction products of dihydric alcohols such as
ethylene glycol, propylene glycol, diethylene glycol,
1,4-butanediol, neopentyl glycol, 1,6-hexanediol or cyclohexane
dimethanol or mixtures of such dihydric alcohols, and dicarboxylic
acids or their ester-forming derivatives, for example succinic,
glutaric and adipic acids or their dimethyl esters, sebacic acid,
phthalic anhydride, tetrachlorophthalic anhydride or dimethyl
terephthalate or mixtures thereof.
[0059] Polyesteramides may be obtained by the inclusion of
aminoalcohols such as ethanolamine in polyesterification
mixtures.
[0060] Polythioether polyols which may be used include products
obtained by condensing thiodiglycol either alone or with other
glycols, alkylene oxides, dicarboxylic acids, formaldehyde,
amino-alcohols or aminocarboxylic acids.
[0061] Polycarbonate polyols which may be used include products
obtained by reacting diols such as 1,3-propanediol, 1,4-butanediol,
1,6-hexanediol diethylene glycol or tetraethylene glycol with
diaryl carbonates, for example diphenyl carbonate, or with
phosgene.
[0062] Polyacetal polyols which may be used include those prepared
by reacting glycols such as diethylene glycol, triethylene glycol
or hexanediol with formaldehyde. Suitable polyacetals may also be
prepared by polymerising cyclic acetals.
[0063] Suitable polyolefin polyols include hydroxy-terminated
butadiene homo- and copolymers and suitable polysiloxane polyols
include polydimethylsiloxane diols.
[0064] In one embodiment, a polyol chain extender may be included
in component B. The chain extender may be used to increase the
length of the carbon chains in the polyurethane foam compositions.
Suitable chain extenders include aliphatic diols, such as ethylene
glycol, 1,3-propanediol, 2-methyl-1,3-propanediol, 1,4-butanediol,
1,5-pentanediol, 1,6-hexanediol, 1,2-propanediol, 1,3-butanediol,
2,3-butanediol, 1,3-pentanediol, 1,2-hexanediol,
3-methylpentane-1,5-diol, 2,2-dimethyl-1,3-propanediol, diethylene
glycol, dipropylene glycol and tripropylene glycol, and
aminoalcohols such as ethanolamine, N-methyldiethanolamine,
N-ethyldiethanolamine and the like. Other chain extenders that may
be used include hydroquinone di(ethyl ether) or primary diamines
such as ethylene diamine, hydrazine, 3,5-diethyl toluene diamine,
or methylene bis-orthochloraniline.
[0065] The polyol used in component B may have any suitable
molecular weight. For instance, the molecular weight of the polyol
may be greater than about 1000, such as from about 2000 to about
10,000. The polyol may also have a hydroxyl number of greater than
about 300, such as greater than about 1000. For instance, the
polyol may have a hydroxyl number of from about 300 to about
3000.
[0066] In addition to a polyol, the B component may also contain a
catalyst. The catalyst may comprise, for instance, an amine
compound or an organometallic complex. Amine catalysts that may be
used include triethylenediamine, dimethylcyclohexylamine,
dimethylethanolamine, tetramethylbutanediamine,
bis-(2-dimethylaminoethyl)ether, triethylamine,
pentamethyldiethylenetriamine, benzyldimethylamine, and the
like.
[0067] Organometallic catalysts that may be used include compounds
based on mercury, lead, tin, bismuth, or zinc. Particular examples
of organometallic catalysts are alkyltincarboxylates, oxides and
mercaptides oxides.
[0068] It should be understood, however, that in some applications
a catalyst may not be needed.
[0069] In addition to a catalyst, the B component may also contain
a plasticizer. In one embodiment, for instance, a phthalate
plasticizer may be used. Examples of plasticizers include alkyl
aryl phthalates, or alkyl benzyl phthalates, including butyl benzyl
phthalate, alkyl benzyl phthalate wherein the alkyl group has a
carbon chain of from seven to nine carbon atoms. Texanol benzyl
phthalate, alkyl phenyl phthalate, symmetrical and unsymmetrical
dialkyl phthalates including diisononyl phthalate, diisodecyl
phthalate, dioctyl phthalate, dihexyl phthalate, diheptyl
phthalate, butyloctyl phthalate, linear dialkyl phthalate wherein
the alkyl groups are independently carbon chains having from seven
to eleven carbon atoms, and butyl cyclohexyl phthalate; and
phosphate ester plasticizers such as, for example, 2-ethylhexyl
diphenyl phosphate, isodecyl diphenyl phosphate, mixed dodecyl and
tetradecyl diphenyl phosphate, trioctyl phosphate, tributyl
phosphate, butylphenyl diphenyl phosphate and isopropylated
triphenyl phosphate; and benzoate plasticizers such as, for
example, Texanol benzoate, glycol benzoate, propylene glycol
dibenzoate, dipropylene glycol dibenzoate and propylene glycol
dibenzoate.
[0070] To form the polyurethane foam, the two components may be
sprayed through the nozzle 22 under pressure. In one embodiment,
the pressure may be relatively low, such as less than about 200
psi. In other embodiments, however, a higher pressure may be
desirable. For instance, the components may be under a pressure of
greater than about 200 psi, such as from about 300 psi to about
1400 psi.
[0071] To form the foam material, in one embodiment, a blowing
agent may be desired. In one embodiment, for instance, the blowing
agent may comprise water. In addition to water, other blowing
agents that may be used include chlorofluorocarbons,
hydrofluorocarbons, or hydrochlorofluorocarbons. Still other
blowing agents that may be used include carbon dioxide, pentane or
various hydrocarbons.
[0072] The amount of blowing agent used in any particular
application depends upon the reactants, the pressure at which the
components are mixed, and various other factors. In general, for
instance, the blowing agent may be present in an amount greater
than zero to greater than about 20 parts by weight. The particular
blowing agent used in the process and the amount of blowing agent
may also have an impact upon the cell structure of the resulting
foam. For instance, use of a particular blowing agent may result in
an open cell structure or a closed cell structure.
[0073] The resulting foam can have any suitable density depending
upon the particular application. The density of the foam, for
instance, can be at least about 0.5 lb/ft.sup.3. In one embodiment,
for instance, the density can be from about 1.5 lbs/ft.sup.3 to
about 2.5 lbs/ft.sup.3, such as from about 1.75 lbs/ft.sup.3 to
about 2 lbs/ft.sup.3. The resulting foam can be compressible and/or
flexible. The foam can also have elastic properties. For instance,
the foam can have an elongation of over 125 percent, such as over
150 percent, such as over 175 percent. For example, in one
embodiment, the foam can have an elongation of from about 150
percent to about 300 percent.
[0074] Once the insulation product 10 is formed as shown in either
FIG. 2 or 3, the laminated product is either wound into rolls as
shown in FIG. 1 or cut and stacked into strips. The insulation
product is then delivered and installed against a surface of a
structure or building. The insulation material can be cut to any
desired width. For instance, the width of the product can be
generally from about 6 inches to about 4 feet, such as from about 6
inches to about 2 feet.
[0075] Referring to FIG. 4, for exemplary purposes only, a surface
50 insulated in accordance with the present disclosure is shown.
More particularly, FIG. 1 is intended to illustrate a
cross-sectional view of an insulated wall cavity such as a ceiling
or attic. It should be understood, however, that laminated products
made according to the present disclosure can be used to insulate
various other areas of a structure or building as well. In this
embodiment, the surface 50 comprises a ceiling that is attached to
studs 52, 53, and 54. In between each pair of studs is the
insulation product 10 made in accordance with the present
disclosure. The insulation product 10 is applied to the surface 50
in order to insulate the ceiling and particularly prevent airflow
through the cavity.
[0076] As shown, in this embodiment, the insulation product 10
comprises an air barrier such as a foam layer 14 laminated to a
fibrous layer 12. When the foam material 14 is combined with the
fibrous layer 12, the foam material can serve as an air barrier for
preventing or reducing air flow from reaching the batt of
insulation. Air flow through the batt of insulation may have
detrimental effects on the ability of the fibrous material to
insulate the surface. Thus, the foam material 14 can block or
substantially block air flow through the cavity and thereby
maintain or even improve the R-value of the product.
[0077] In the embodiment illustrated, the foam layer 14 is
positioned directly adjacent to the surface 50. In an alternative
embodiment, the insulation product 10 may include two different
foam layers. The fibrous material 12, for instance, may be
positioned in between two layers of foam material.
[0078] In one embodiment, the width of the insulation product 10
may be such that the insulation product forms a friction fit in
between the studs of the cavity. Of particular advantage, since the
foam material 14 is flexible, the foam material will conform to the
contours of the surface and fill any cracks or crevices
present.
[0079] These and other modifications and variations to the present
invention may be practiced by those of ordinary skill in the art,
without departing from the spirit and scope of the present
invention, which is more particularly set forth in the appended
claims. In addition, it should be understood that aspects of the
various embodiments may be interchanged both in whole or in part.
Furthermore, those of ordinary skill in the art will appreciate
that the foregoing description is by way of example only, and is
not intended to limit the invention so further described in such
appended claims.
* * * * *